Professional Documents
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Table of Contents
Cookware Industry 3
Metallurgy Industry 7
Medical Industry 9
Automobile Industry 11
Papermaking Industry 13
Crane Industry 15
Chemical Industry 17
1
Nylon Industry 19
Crane Industry 23
Telecom Industry 25
Metallurgy Industry 27
Products 29
2
Cookware Industry
3
Harmonic Treatment for Electroplating
Process
Supor Cookware, Zhejiang, China
►► Six Active Power Filter APF2000 series (200A) units were deployed by the three
major SCRs and connected to the power grid in parallel to filter harmonics.
►► System Structure:
1# Transformer for copper dismantling
10KV/0.4KV
2500KVA A、B、C 0.4KV Bus bar
Testing point
Air compressors
Power for Power for Power for
SCR #1 SCR #2 SCR #3
500KVA 500KVA 500KVA
Solution
Before
After
Delta's power quality solution solved the overheating and noise problems for the
Benefits electroplating lines and provided them with more stable facilities, reduced maintenance
costs, and lowered safety risks.
4
Metal Processing Industry
►► Jiangxi Copper is China's largest and most modern metal processing manufacturer
specializing in copper extraction and processing.
►► A copper dismantling project which used wire stripping machines, motor dismantling
machines, and many other machines controlled by high-power inverters, was
Background creating significant harmonic distortion, voltage fluctuations, and large amounts of
reactive power that reduced the power factor down to 0.6 ~ 0.7.
►► Harmonic distortion problems led to system malfunctions and production
breakdowns. Reactive power problems led to a huge waste of energy and large
power bills.
5
Harmonic and Reactive Power
Treatment for Metal Dismantling
Jiangxi Copper, Jiangxi, China
►► One Static Var Generator SVG2000 series (500kVar) unit was deployed by the
power distribution system for the large dismantling machines to perform bidirectional
compensation for reactive power while suppressing harmonics.
►► System Structure:
Testing
point
►► Performance: The power factor of the power distribution system improved from 0.71
to 0.97. The harmonic current dropped from 11% ~ 15% to 2% ~ 4%.
Delta's
Solution
Before
After
While improving the facility's efficiency and stability, Delta's power quality solution also
Benefits helped Jiangxi Copper with enhanced power efficiency for power savings, and with
avoiding penalties from utility companies, making the best usage of a limited resource.
6
Metallurgy Industry
Background ►► Using inverters, pumps and blowers in the electrorefining workshop added an extra
load burden on the bus bar and created harmonic problems that led to voltage
fluctuations, and interference and damage to other equipment.
►► The system's low power factor represented an enormous energy waste and resulted
in penalties of up to RMB 180,000 per month.
7
Harmonic and Reactive Power Treatment
for Metal Electrolyzing
Jiangxi Copper Qingyuan Factory,
Guangdong, China
Testing
point
►► Performance: The power factor improved from 0.83 to 0.96. The harmonics
Delta's distortion dropped from 6% ~ 8% to 3% which met the government regulated
standard.
Solution
Before
After
By providing a better power factor, Delta's power quality solution helped the factory
save big on power bills, avoid penalties charged by utility companies, and earn
Benefits high power factor rewards. The harmonic treatment effectively solved the facility's
interference problems and ensured a longer operational lifespan for cost savings.
8
Medical Industry
9
Securing Medical Power Stability
First Clinical Hospital of Jilin University,
Jilin, China
►► One Active Power Filter APF2000 series (200A) unit deployed by the low-voltage
incoming power lines for the four major transformers (1600kVA) through parallel
connection to the power grid.
►► System Structure:
7# Transformer 10KV/0.4KV
1600KVA
A、B、C
0.4KV Bus bar
Current
transfor-
mer
sample
CT
Delta's
Solution
Before
After
Solving the harmonic distortion which caused the electrical interference, Delta's
Benefits solution ensured proper operation of medical instruments and prevented potential
medical risks to patients due to equipment malfunctions.
10
Automobile Industry
►► JAC Motors in Anhui, China adopted a large number of machines with non-linear
loads on its welding, stamping and assembly lines that caused serious voltage and
current harmonic distortion to the low-voltage power grid.
Background ►► Harmonic distortion and reactive power caused enormous energy waste, damage to
capacitor cabinets, overheating and excessive oscillation of magnetic components,
and voltage fluctuations that led to equipment malfunctions, jeopardized production
efficiency and quality, and posed safety risks to the production environment.
11
Harmonics and Reactive Power Treatment
for Automobile Manufacturing
JAC Motors, Anhui, China
►► One Static Var Generator SVG2000 series (500kVAR) unit deployed by the
incoming power line of the final assembly workshop with 3-phase 3-wire wiring.
►► System Structure:
Current
transformer
sample CT
Testing
point
►► Performance: The power factor improved from 0.71 to 0.98. The harmonic current
dropped from 15% ~ 25% to 3% ~ 5%.
Delta's
Solution
Before
After
Delta's Power Quality Solution solved the harmonic distortion faced by the car
Benefits assembly lines of JAC Motors and restored operations back to normal. The reduced
reactive power also improved energy efficiency for energy savings.
12
Papermaking Industry
13
Harmonic and Reactive Power Treatment
for Paper / Tobacco Processing
Liqun Environmental Protection Paper
Co., Ltd., Hangzhou, China
►► Two Active Power Filter APF2000 series (200A) units deployed by the incoming
power line for the two major transformers of the production line.
►► System Structure:
2# Transformer 10KV/0.4KV
1# Transformer 10KV/0.4KV
1600KVA
1600KVA
A、B、C A、B、C
0.4KV Bus bar 0.4KV Bus bar
Current Current
transformer transformer
sample CT sample CT
Testing
point
►► Performance: The power factor improved from 0.89 to 0.99. The harmonic current
decreased from 11% down to 5%.
Delta's
Solution
Before
After
Improving harmonic distortion and reactive power problems, Delta's power quality
solution ensured the paper / tobacco production lines for normal facility operation, an
Benefits extended facility lifespan, better workplace safety, and better energy efficiency which
resulted in RMB 2,000 ~ 3,000 of government rewards every month for power savings.
14
Crane Industry
AFE2000
Active Front End
►► Ningbo port is one of the five largest ports in China. Its cargo throughput volume
reached the top 3 in China for 2013.
►► A crane system is a major device used in cargo lifting and transporting at the
port. Its rectifier characteristics during operation create harmonics distortion and
consume reactive current which cause power quality problems and generates a low
Background power factor of 0.2 ~ 0.9.
►► The crane system is located a distance away from the mains power supply and
it experienced voltage drops and difficulty in activation. The regenerative energy
generated by the crane system was wasted through dissipated heat using the brake
resistor.
15
Refurbishment of Old Crane System for
Energy Saving Operation
Ningbo Port, Beilun District, China
►► One Delta Active Front End unit was deployed to transform the old crane system. It
was serially connected in between the crane system and the mains power supply to
filter harmonics and convert regenerative energy into reusable electricity for other
facilities to use.
►► System Structure:
Kp
AFE2000
KM1
R
1000V/420V
Rectifier Crane Crab Brake Brake
S Hoist
Circuit Travel Traverse Unit Unit
T
400KVA
Delta's Crane
Travel
Crane
Travel Resistor Box
Motor Motor
Solution Crane
Hoist Travel
Motor Motor
►► Performance: The power factor improved from 0.87 ~ 0.94 to 0.99. The harmonic
current was reduced from 14.5% to 2%. The power regeneration function provides
energy savings of 30.2%.
Work
Time Consumption Consumption Harmonic Harmonic Power
AFE Quantity
min kWh Per UnitkWh Voltage Current Factor
(TEU)
Lift
Approx. Approx. 0.94
Before 30 28.68 10 2.868
7.2% 14.5% Down
0.87
Approx. Approx.
After 30 20.02 10 2.002 0.99
1.7% 2%
Delta's power quality solution solved the overheating and noise problems for the crane
system and provided it with more stable facilities, reduced maintenance costs, and
Benefits lowered safety risks. In addition, its power regeneration function helps the system
save more than 30% in energy.
16
Chemical Industry
17
Harmonic and Reactive Power Treatment
for Chemical Industry
Zhongtai Chemical Production,
Xingjiang, China
►► One Static Var Generator - SVG2000 series (300 kVar) unit is connected to the low
voltage side of a transformer to perform bidirectional compensation for reactive
power and suppress harmonics.
►► System Structure:
2# Transformer 10KV/0.4KV
3300KVA
A、B、C 0.4KV Bus bar
Current
transformer
sample CT
Testing
point
Load 1 Load N
►► Performance: Power factor improved from 0.82 to 0.95 and harmonic current
dropped from 15% ~ 25% to 2% ~ 4%.
Delta's
Solution
Before
After
Delta's power quality solution improved the production efficiency and stability for the
Xinjiang Zhongtai Chemical Company. The SVG2000 series solved the overheating
Benefits problems of copper busbars, capacitor cabinets and transformers while reducing
noise, which ensures the facility of a longer lifespan and lowers the risk of chemical
explosion from an interrupted production line.
18
Nylon Industry
19
Harmonic and Reactive Power Treatment
for Textile Manufacturing
Jinjiang Nylon Production, Fujian,
China
►► Two Active Power Filter APF2000 Series units are connected to the low voltage side
of the transformer to efficiently suppress harmonic current and voltage.
►► System Structure:
1# Transformer 10KV/0.4KV
1600KVA
Testing
point 3
►► Performance: This corrects the harmonic wave from a distorted waveform into a
perfect sinusoidal form and reduces harmonic current and voltage.
Delta's
Solution
Before
After
Delta's power quality solution provides high power efficiency for nylon production and
ensures good product quality for Fujian Jinjiang Technology. The APF2000 series
Benefits helps to solve the overheating problems of the production line, transformer and bus
bars to provide clean power and ensure good product quality with high production
stability.
20
Printing and Dyeing Industry
►► Shaoxing Tengda Printing and Dyeing Co., Ltd. is a large export-oriented enterprise
that incorporates trading, manufacturing, and processing. It specializes in printing
and dying, and produces polyester knitted fabric, cotton knitted fabric, and polar
fleece that are widely used in garments, blankets, and more.
►► The printing and dyeing production line uses a large number of inverters to control
power efficiency, which creates serious harmonic distortion of voltage and current in
Background the low voltage grid and lowers the power factor.
►► Harmonic problems cause overheating of electric facilities and damage to inverters,
which leads to production line interruptions, reduces product quality and lowers
productivity. Serious damage to transformers and capacitor cabinets result in minor
power factor improvement and little difference in before-and-after application to the
capacitor cabinet.
21
Power Factor Improvements for Printing
and Dyeing Industry
Shaoxing Tengda Printing and Dyeing
Co., Ltd, China
►► Two Active Power Filter APF2000 Series units were deployed by the power
distribution system and connected to the low voltage side of the transformer to
improve power factor and suppress harmonics.
►► System Structure:
1# Transformer 2# Transformer
10KV/0.4KV 10KV/0.4KV
2000KVA 2000KVA
A、B、C A、B、C
0.4KV Bus bar 0.4KV Bus bar
Current Current
transformer transformer
sample CT sample CT
Testing
point
APF2000 APF2000
►► Performance: The power factor has improved from 0.91 to 0.94. The harmonic
Delta's current dropped from 15% ~ 20% to lower than 5%.
Solution
Before
After
Delta's power quality solution effectively improved the power factor for the Shaoxing
Tengda Printing and Dyeing Industry. Good power quality reduces damage to inverters,
Benefits ensures a longer facility life, and leads to good production quality and productivity
while saving on energy costs.
22
Crane Industry
23
Harmonic and Power Factor Treatment
for Crane Industry
Shekou Container Terminal, China
(Quay Crane Import / Export Port)
►► Four Static Var Generator SVG2000 Series (500KVAR) units are deployed by the
quay crane systems #4 and #6. The SVG2000 is connected to the low voltage
side of transformers providing harmonics filtering and bidirectional reactive power
compensation to improve power factor.
►► System Structure:
1200KVA
10KV/525V
M M M M
SVG2000 SVG2000 Hoist Crane Travel Crab Traverse Pitching Drive
250KW 30KW 200KW 200KW
►► Performance: The power factor improved from 0.2 ~ 0.8 to 0.99. The harmonic
current dropped from 10% ~ 50% to 2% ~ 5%.
Delta's
Solution
Before
After
Delta's Power Quality Solution substantially improved the power factor of the SCT
port from only 0.2 ~ 0.6 to 0.95, meeting government regulations and avoiding penalty
Benefits costs. This is the benchmark of Delta's SVG2000 application for quay crane systems
in China. It provides excellent harmonic filtering and reactive power compensation that
helps SCT port save a great amount of energy and costs.
24
Telecom Industry
►► China United Network Communications Group Co., Ltd. ("China Unicom") is a large
company with branches located in 31 provinces providing services that include:
mobile communications, domestic and international fixed telephone network and
facilities (including wireless local loops), information services, image and multimedia
communications and information services, and more.
Background ►► The Taiyuan office uses a large number of UPSs and switching power supplies in
the IDC room to ensure uninterrupted data and information transmission, but this
causes harmonics problem for the low voltage grid that leads to transmission failure.
►► Power quality problems caused power activation failure and damaged the capacitor
cabinet that led to loss of data and inaccurate billing, which impacted company
profits.
25
Harmonic and Reactive Power Treatment
for Telecom Industry
China Unicom
►► One Active Power Filter APF2000 Series is connected to the UPS power supply
side. The UPS is used to expand the capacity of an IDC engine room.
►► System Structure:
1# Transformer
10KV/0.4KV A、B、C
800KVA 0.4KV Bus bar
Current
transformer
sample CT
Testing
point
Power Cabinet
Output Side Office Lighting HVAC Others
APF2000
►► Performance: Effectively reduces the harmonic current from 50% ~ 60% to below 5%.
Delta's
Solution
Before
After
Delta's power quality solution efficiently suppresses harmonic current down to 5% and
ensures the Taiyuan telecom branch office with good power quality. This solves the
Benefits IDC control room's loss of data problem and provides uninterrupted data transmission
to ensure accurate billing and secure the company's profits.
26
Metallurgy Industry
►► Zhuzho Smelter Group Co., Ltd. in Hunan, China specializes in metal manufacturing,
processing, and recycling. It is one of China's major manufacturers of descloizite
products.
►► Metal manufacturing and processing required many rectifiers and large power
Background inverters that generated serious harmonics and reactive power affecting other
manufacturing facilities. These problems led to facility malfunctions and damaged
capacitor cabinets that constantly stopped production line operations and increased
maintenance costs.
27
Harmonic and Reactive Power Treatment
for Iron Precipitation and Direct Leaching
Zhuzho Smelter Group Co., Ltd., Hunan,
China
►► Five Active Power Filters APF2000 series (300A) units were deployed by the five
rectifiers and inverters used for the iron precipitation and direct leaching process,
and connected in parallel to the power grid to suppress harmonics and reduce
reactive power.
►► System Structure: 220KV/10KV
APF2000 APF2000
►► Performance: The current waveform was corrected back to a sinusoidal shape. The
harmonic current decreased from 26.4% to 4%, meeting the government regulated
Delta's standard.
Solution
Before
After
Delta's power quality solution effectively improved the facility malfunction and capacitor
cabinet damage problems faced by the Zhuzho Smelter Group on its production lines.
Benefits The more stable facility ensured better production quality, lower maintenance costs
and lower safety risks for safe, stable and efficient manufacturing lines.
28
Active Front End AFE2000
Active Front End (AFE) is a controllable rectifier with advantages such as providing
bidirectional power exchange between AC and DC power and regenerating reusable
power to the mains to reduce the cost of power. The AFE uses PWM modulation
to greatly reduce distinctive peaks of current and form a perfect sine wave current.
The power factor is corrected up to 1 and the ratio between load capacity and power
capacity is 1:1. In addition, the AFE eliminates high order harmonics, provides very
low harmonic current THD < 5% while improving the power factor, which allows you to
save on the cost of purchasing additional electrical equipment for better power quality.
The AFE also offers stable power quality unaffected from mains power fluctuations
and can be applied to a serial connection.
Power quality is a major influence on power efficiency. A clean and efficient power
system normally generates a sinusoidal current waveform, but the electrical
equipment used in today's industrial automation industry generates non-sinusoidal
currents that tend to cause power quality problems. Voltage or current distortion,
reactive power impact, and unbalanced loads, are common problems that lower
power reliability and power efficiency and also increase operation costs. Major
concerns in the industrial automation industry are how to improve power quality and
how to manage power grids.
Delta's APF2000 adopts the industry's highest standard 32-bit digital microprocessor
to instantly compensate for all types of harmonics for ultimate power quality
improvement. Perfect control of harmonic distortion reduces power loss and heat
generation. The APF2000 is compact in design for all users to manage their space
efficiently and is mounted with a 65,536-color TFT HMI for more realistic images
and a vivid display. The ultimate mission of Delta's APF2000 is to provide you with
improved power quality, lower energy loss and lower maintenance costs.
29
Static Var Generator SVG2000
Delta's SVG2000 is a Static Var Generator (SVG) that improves power quality.
Compared to a traditional Static Var Compensator (SVC) with an LC system, Delta's
SVG2000 offers many excellent features including enhanced stability, extended
product lifetime, fast response, wide power range, large capacity, smooth tuning,
low harmonics, stable system voltage, and many more, for greatly improved power
quality.
The SVG2000's compact design allows you to manage your installation space
efficiently and the high standard color HMI provides realistic images and a vivid
display. The SVG2000's excellent feature set helps to reduce energy loss, lower
maintenance costs, and maximize your utility.
30
Industrial Automation Headquarters
Delta Electronics, Inc.
Taoyuan Technology Center
No.18, Xinglong Rd., Taoyuan City,
Taoyuan County 33068, Taiwan
TEL: 886-3-362-6301 / FAX: 886-3-371-6301
Asia
Delta Electronics (Jiangsu) Ltd.
Wujiang Plant 3
1688 Jiangxing East Road,
Wujiang Economic Development Zone
Wujiang City, Jiang Su Province,
People's Republic of China (Post code: 215200)
TEL: 86-512-6340-3008 / FAX: 86-769-6340-7290
Americas
Delta Products Corporation (USA)
Raleigh Office
P.O. Box 12173,5101 Davis Drive,
Research Triangle Park, NC 27709, U.S.A.
TEL: 1-919-767-3800 / FAX: 1-919-767-8080
Europe
Deltronics (The Netherlands) B.V.
Eindhoven Office
De Witbogt 20, 5652 AG Eindhoven, The Netherlands
TEL: 31-40-2592850 / FAX: 31-40-2592851
*We reserve the right to change the information in this catalogue without prior notice.
DELTA_IA-PQ_APF-SuccessStories_C_EN_20151014